Abstract:

A method of making a treating wash includes mixing brass granules with
acetone, mixing carbon nanotube material, iron pyrite granules and copper
granules in the acetone brass mixture, and straining the liquid from the
remaining solid material. Methods of treating materials such as brass
granules, iron pyrite granules, carbon nanotube material, and brass
granules comprises washing the materials in the treating wash, followed
by straining and drying the materials.

Claims:

1. A method for forming a lead electrode, comprising:providing a batch of
molten lead;preparing a wash liquid comprising acetone, brass granules,
carbon nanotube material, iron pyrite granules, and copper granules,
mixed at high speed and strained;treating brass granules with the wash
liquid, and straining and drying the brass granules to form treated brass
granules;treating iron pyrite granules with the wash liquid, and
straining and drying the brass granules to form treated iron pyrite
granules;treating copper granules with the wash liquid, and straining and
drying the brass granules to form treated copper granules;adding the
treated brass granules, the treated iron pyrite granules, and the treated
copper granules to the molten lead;pouring the molten lead into a pour
mold coated with a thin layer of brass granules;allowing the lead to
solidify into an ingot and then rolling the ingot in a pressure roller.

2. The method of claim 1 wherein:providing a batch of molten lead
comprises providing about 635 Kg of molten lead;preparing a wash liquid
comprising acetone, brass granules, carbon nanotube material, iron pyrite
granules, and copper granules, mixed at high speed and strained;treating
brass granules comprises treating about 9 Kg of brass granules having a
size of about 100 mesh or finer for each about 635 Kg of molten
lead;treating iron pyrite granules comprises treating about 2.3 Kg of
powdered iron pyrite having a size of about 0.025 inch or finer for each
about 635 Kg of molten lead; andtreating copper granules comprises
treating about 4.5 Kg of copper granules having a size of about 100 mesh
or finer for each about 635 Kg of molten lead.

4. The method of claim 3 wherein:mixing brass granules with acetone
comprises mixing about 454 grams of brass (about 100 mesh or finer) per
gallon of acetone in a commercial blender at high speed for about 10
minutes or until a gold color appears at the surface of the acetone when
the blender is stopped;mixing carbon nanotube material comprises mixing
about one gram of multi-walled carbon nanotube material per gallon of
acetone at high speed for about 5 minutes;mixing iron pyrite comprises
mixing about 33.5 grams of iron pyrite per gallon of acetone, the iron
pyrite having an average grain size of about 0.125 inch for a minimum of
about 3 minutes at high speed;mixing copper comprises mixing about 517
grams of copper per gallon of acetone, the copper having a mesh size of
about 35 mesh or finer for about 8 minutes until a slurry begins to form
on the surface after the blender is turned off.

5. The method of claim 1 wherein rolling the ingot in a pressure roller
comprises rolling the ingot in a pressure roller as it is cooling.

6. The method of claim 1 wherein rolling the ingot in a pressure roller
comprises rolling the ingot to a thickness of about 0.25 inches.

7. The method of claim 1 further including cutting the ingot to a finished
size.

8. The method of claim 7 wherein the finished size is about 3 ft. by about
4 ft.

9. The method of claim 1 wherein providing a batch of molten lead
comprises providing a molten calcium-tin lead composition.

10. A method for forming a lead electrode, comprising:providing a batch of
molten lead including molten silver;preparing a wash liquid comprising
acetone, brass granules, carbon nanotube material, iron pyrite granules,
and copper granules, mixed at high speed and strained;treating brass
granules with the wash liquid, and straining and drying the brass
granules to form treated brass granules;treating iron pyrite granules
with the wash liquid, and straining and drying the brass granules to form
treated iron pyrite granules;adding the treated brass granules, and the
treated iron pyrite granules to the molten lead;pouring the molten lead
into a pour mold coated with a thin layer of brass granules;allowing the
lead to solidify into an ingot and then rolling the ingot in a pressure
roller.

11. The method of claim 10 wherein:providing a batch of molten lead
comprises providing about 635 Kg of molten lead;preparing a wash liquid
comprising acetone, brass granules, carbon nanotube material, iron pyrite
granules, and copper granules, mixed at high speed and strained;treating
brass granules comprises treating about 11.25 Kg of brass granules having
a size of about 100 mesh or finer for each about 635 Kg of molten lead;
andtreating iron pyrite granules comprises treating about 4.55 Kg of
powdered iron pyrite having a size of about 0.025 inch or finer for each
about 635 Kg of molten lead.

12. The method of claim 10 wherein providing a batch of molten lead
including molten silver comprises providing a batch of molten lead
including about 0.46% molten silver by weight.

14. The method of claim 13 wherein:mixing brass granules with acetone
comprises mixing about 454 grams of brass (about 100 mesh or finer) per
gallon of acetone in a commercial blender at high speed for about 10
minutes or until a gold color appears at the surface of the acetone when
the blender is stopped;mixing carbon nanotube material comprises mixing
about one gram of multi-walled carbon nanotube material per gallon of
acetone at high speed for about 5 minutes;mixing iron pyrite comprises
mixing about 33.5 grams of iron pyrite per gallon of acetone, the iron
pyrite having an average grain size of about 0.125 inch for a minimum of
about 3 minutes at high speed.

15. The method of claim 10 wherein rolling the ingot in a pressure roller
comprises rolling the ingot in a pressure roller as it is cooling.

16. The method of claim 10 wherein rolling the ingot in a pressure roller
comprises rolling the ingot to a thickness of about 0.25 inches.

17. The method of claim 10 further including cutting the ingot to a
finished size.

18. The method of claim 17 wherein the finished size is about 3 ft. by
about 4 ft.

Description:

CROSS-REFERENCE TO RELATED APPLICATIONS

[0001]This application is a divisional of co-pending U.S. patent
application Ser. No. 12/268,315, filed Nov. 10, 2008, the entirety of
which is incorporated by reference herein.

BACKGROUND OF THE INVENTION

[0002]1. Field of the Invention

[0003]The present invention relates to solid-material compositions having
enhanced physical and electrical properties as well as products formed
using the material and methods for making the material and the products.

[0004]2. The Prior Art

[0005]Products such as electrodes, electrode hangers, and bus bars for
hydrometallurgy electrowinning (electroextraction) are known in the art.
The electrodes are usually made from lead or lead alloys and the
electrode hangers and bus bars are usually made from copper.

[0006]Body armor is usually formed from a series of plates each comprising
a plurality of layers of different materials. Materials such as alloyed
ceramics have been successfully employed in body armor plates.

BRIEF DESCRIPTION

[0007]A treating wash according to one aspect of the present invention
comprises acetone, brass granules, carbon nanotube material, iron pyrite
granules, and copper granules. A method of making a treating wash
includes mixing brass granules with acetone, mixing carbon nanotube
material, iron pyrite granules and copper granules in the acetone brass
mixture, and straining the liquid from the remaining solid material.
Methods of treating materials such as brass granules, iron pyrite
granules, carbon nanotube material, and brass granules comprises washing
the materials in the treating wash, followed by straining and drying the
materials.

[0008]According to another aspect of the present invention, a method for
forming a lead electrode, comprises providing a batch of molten lead,
preparing a wash liquid comprising acetone, brass granules, carbon
nanotube material, iron pyrite granules, and copper granules, mixed at
high speed and strained, treating brass granules with the wash liquid,
and straining and drying the brass granules to form treated brass
granules, treating iron pyrite granules with the wash liquid, and
straining and drying the brass granules to form treated iron pyrite
granules, treating copper granules with the wash liquid, and straining
and drying the brass granules to form treated copper granules, adding the
treated brass granules, the treated iron pyrite granules, and the treated
copper granules to the molten lead, pouring the molten lead into a pour
mold coated with a thin layer of brass granules, allowing the lead to
solidify into an ingot and then rolling the ingot in a pressure roller.

[0009]According to another aspect of the present invention, a method for
forming one of a bus bar and a hanger bar for an electrode comprises
providing a length of copper tubing, placing a first plug at a first end
of the copper tubing, disposing a copper strip inside the copper tubing,
preparing a wash liquid comprising acetone, brass granules, carbon
nanotube material, iron pyrite granules, and copper granules, mixed at
high speed and strained, treating brass granules with the wash liquid,
and straining and drying the brass granules to form treated brass
granules, treating magnetite with the wash liquid, and straining and
drying the brass granules to form treated magnetite, treating iron pyrite
granules with the wash liquid, and straining and drying the brass
granules to form treated iron pyrite granules, treating copper granules
with the wash liquid, and straining and drying the brass granules to form
treated copper granules, mixing and coating with a penetrating oil the
treated brass granules, the treated magnetite, the treated iron pyrite
granules, and the treated copper granules to form a fill mixture, filling
the copper tubing with the fill mixture; and placing a second plug at a
second end of the copper tubing.

[0010]According to another aspect of the present invention, a body-armor
plate includes a first layer of treated brass granules, a first layer of
treated glass-filled polymer, a first layer of treated iron pyrite
granules, a metal sheet, a second layer of treated iron pyrite granules,
a second layer of treated glass-filled polymer, and a second layer of
treated brass granules. A method for making a body-armor plate comprises
providing a body-armor plate mold, placing a layer of treated brass
granules in the body-armor plate mold, placing a layer of treated
glass-filled polymer over the layer of treated brass granules, placing a
layer of treated iron pyrite over the layer of treated glass-filled
polymer, placing a metal sheet over the layer of layer of treated iron
pyrite, placing a layer of treated iron pyrite over the metal sheet;
placing a layer of treated glass-filled polymer over the layer of treated
iron pyrite, placing a layer of treated brass granules over the layer of
glass-filled polymer, placing a cover on the mold, heating the mold and
placing the mold in a press.

BRIEF DESCRIPTION OF THE DRAWING FIGURES

[0011]FIG. 1 is a diagram illustrating a process for making a treating
wash according to one aspect of the present invention.

[0012]FIG. 2 is a diagram illustrating a process for making a calcium-tin
lead anode according to another aspect of the present invention.

[0013]FIG. 3 is a diagram showing a radial cross sectional view of an
illustrative electrode hanger bar according to another aspect of the
present invention.

[0014]FIG. 4 is a diagram showing a radial cross sectional view of a
second illustrative electrode hanger bar according to another aspect of
the present invention.

[0015]FIG. 5 is a diagram showing an axial cross sectional view of both
the electrode hangars of FIGS. 4 and 5 taken along the line A-A.

[0016]FIG. 6 is a diagram illustrating a process for making a hangar bar
or bus bar according to another aspect of the present invention.

[0017]FIG. 7 is a diagram illustrating a process for making a body-armor
plate according to another aspect of the present invention.

DETAILED DESCRIPTION

[0018]Persons of ordinary skill in the art will realize that the following
description of the present invention is illustrative only and not in any
way limiting. Other embodiments of the invention will readily suggest
themselves to such skilled persons.

[0019]The present invention relates to solid-material compositions having
enhanced physical and electrical properties as well as products formed
using the material and methods for making the material and the products.

[0020]Various products can be made using the composition of the present
invention. One aspect of the present invention is a wash or bath used to
treat ingredients used to form the composition. Since the volume of the
wash or bath will vary with the particular application, an illustrative
example is given for formulating the wash using one gallon of acetone.
Persons skilled in the art will appreciate that the amounts of the
ingredients disclosed in the example can be linearly scaled to formulate
larger or smaller batches of the wash.

[0021]In one illustrative example shown in FIG. 1, at reference numeral
10, brass is mixed with acetone in a commercial blender. In the example,
about 454 grams of brass (about 100 mesh or finer) is mixed with one
gallon of acetone in a commercial blender at high speed for about 10
minutes or until a gold color appears at the surface of the acetone when
the blender is stopped. At reference numeral 12, carbon nanotube material
is added and mixed. In the illustrative example, about one gram of
multi-walled carbon nanotube material is added and mixed at high speed
for about 5 minutes. At reference numeral 14, iron pyrite is added and
mixed. In the illustrative example, about 33.5 grams of iron pyrite
having a grain size of about 0.125 inch is added and mixed for a minimum
of about 3 minutes at high speed. At reference numeral 16, copper is
added and mixed. In the illustrative example, about 517 grams of copper
(about 35 mesh or finer) is added and mixed at high speed for about 8
minutes until a slurry begins to form on the surface after the blender is
turned off. The order in which the carbon nanotube material, the iron
pyrite, and the copper are added is not critical.

[0022]When the ingredients have all been mixed as described, the liquid is
strained and may be used as a wash or bath. All of the strained solid
matter may be stored for further use as disclosed herein. Once materials
are processed, the wash liquid used may be collected and recycled by
adding it to new batches of the wash liquid.

[0023]Once the wash liquid is formulated, constituent materials of
products to be fabricated are washed using it. A sticky film merges with
the constituent materials. The constituent materials are bonded together
by drying and application of pressure, either in an oven or at room
temperature.

[0024]According to one aspect of the present invention, the composition is
usefully employed in fabricating calcium-tin lead anode and cathode
electrodes for hydrometallurgy electrowinning (electroextraction)
processing applications such as refining processes performed in the
mining industry and batteries. According to one example of a process for
forming an anode described with reference to FIG. 2, at reference numeral
20, a batch of lead is melted. In the illustrative example, about 635 Kg
of molten lead containing appropriate amounts of calcium and tin as is
known in the art is provided in a suitable vessel at a temperature of
about 800° F. At reference numeral 22, brass is treated with the
wash liquid disclosed above. In the illustrative example, about 9 Kg of
brass granules (about 100 mesh) are treated with the wash described above
by running it over the granules. The wash liquid is drained off and the
treated brass granules are allowed to dry. At reference numeral 24, iron
pyrite is treated with the wash liquid. In the illustrative example,
about 2.3 Kg of powdered iron pyrite (about 0.025 inch granules) are also
treated as above. At reference numeral 26, copper is treated with the
wash liquid. In the illustrative example, about 4.5 Kg of copper granules
(about 100 mesh) are treated as above and allowed to dry. At reference
numeral 28, the treated brass, iron pyrite, and copper are added to the
molten lead. A mold in the desired shape of the anode is provided. A thin
layer of about 100 mesh brass is evenly sprinkled on the full bottom of
the lead pour mold plate, this allows the material to flow evenly from
top to bottom as the lead is being poured and is cooling.

[0025]The bottom of the mold is lined with a mixture of the treated
materials and the lead is then poured into the mold at reference numeral
30. As the treated-lead anode ingot is being cooled, it is removed from
the mold at reference numeral 32 and transported to a rolling press
where, at reference numeral 34, it is rolled to a desired thickness such
as about 0.25 inches and cut to size into finished anodes having desired
dimensions such as about 3 ft. by about 4 ft. by about 0.25 inches.

[0026]Anodes formed in accordance with the present invention are more
conductive than conventional lead anodes. It is believed that these
anodes will last longer than conventional anodes.

[0027]According to another aspect of the present invention, the
composition is usefully employed in hanger bars used to support and
supply current to anodes and cathodes. Different views of two
illustrative examples of hanger bars according to the present invention
are shown in FIGS. 3, 4, and 5. A process for fabricating the hangar bar
is illustrated in FIG. 6. According to one illustrative embodiment of a
hanger bar 40 according to the present invention, a suitable length of
copper tubing 42 having, for example, a rectangular cross section (FIG.
3) or a circular cross section (FIG. 4), is provided (reference numeral
60 of FIG. 6). In one illustrative embodiment, the rectangular tubing may
have wall dimensions of, for example, about 1.75 inches by 0.75 inches
and a wall thickness of about 0.125 inches. As will be appreciated by
persons of ordinary skill in the art, the wall thickness may be selected
as a function of the weight of the electrode to be supported. One end of
the tube is capped at reference numeral 62 and copper strip 44 having a
length smaller than the length of the copper tubing by twice the length
of a copper plug to seal the hanger bar and a width selected to provide a
slip fit into the tubing is placed inside the copper tubing at reference
numeral 64. Preferably, perforated steel strips 46 are affixed to one or
both faces of the copper strip 44 by, for example, spot welding,
soldering, or brazing prior to inserting the strip into the tubing. At
reference numeral 66, the tube is filled with a mixture of brass,
multi-walled carbon nanotube material, iron pyrite, and copper as
described above and shown at reference numeral 48.

[0028]Plug 50, made out of a material such as copper, are used to seal the
tubing and may be held in place by, for example, press fitting, welding,
brazing or soldering. A copper plug 50 having a length of about 2 inches
has been found to be satisfactory for this purpose although other lengths
could be employed.

[0029]Prior to filling the tubing, the mixture of brass, iron pyrite, and
copper 48 as described above is washed using the acetone solution and
drained as described above. Additionally, about 2 gms of magnetite washed
and drained using the acetone solution is added to the mixture. The
drained mixture is coated with penetrating oils such as oils sold under
the trademark WD-40 and is then packed into the tubing around the
inserted strip. At reference numeral 68, a second plug 50 is inserted
into the other end of the tubing and may be held in place by, for
example, press fitting, welding, brazing or soldering.

[0030]According to another aspect of the present invention, a bus bar may
be formed using the same process used to form the hanger bar. A center
copper strip 44 is sandwiched between perforated steel sheets 46 and is
disposed in a suitable length of copper tubing 42 as previously shown in
FIGS. 3, 4, and 5. A mixture of copper, brass iron pyrite, and magnetite
(reference numeral 48) treated as described herein is poured into the
tubing, which is then capped with a plug 50 on each end. The length of a
bus bar can and does very from application to application, the particular
length chosen to fit the application. One advantage of using such a bus
bar is to provide a more conductive lead to both the anode and cathode,
thus providing more current and less voltage drop to the cell.

[0031]According to another aspect of the present invention, electrodes
including anodes and cathodes for zinc hydrometallurgy electrowinning
(electroextraction) processes is formed using substantially the same
mixing process as used for the copper anode with only one exception. That
exception is the substitution of substantially equal amounts of
additional brass and iron pyrite in place of the copper at reference
numeral 26 in the process illustrated in FIG. 2. The brass should be high
in zinc not copper; a brass composition having by weight about 68.5%
copper, about 1.5% lead, and about 30% zinc has been found to be suitable
for this application. The zinc hydrometallurgy electrode is made using
the same process shown in FIG. 2 used to form the lead electrode, except
that about 0.46% silver is substituted for the calcium-tin and the
modified mixture containing the additional brass and iron pyrite is used
in place of the copper.

[0032]According to another aspect of the present invention, the
composition is usefully employed to form a plate that may be used in body
armor. According to one example of a process for fabricating body armor
according to the present invention, a mold for an armor plate is
provided. At reference numeral 70, the mold is sprayed with a mold
release agent. At reference numeral 72, the top and bottom mold plates
are completely covered with brass powder (about 100 mesh). A depth of
about 0.03125 inch has been found to be satisfactory. At reference
numeral 74, a layer of glass-filled nylon polymer is washed using the
wash liquid and is placed over the brass granules. A depth of about 0.125
inch has been found to be satisfactory. At reference numeral 76, a layer
of iron pyrite is placed over the glass-filled polymer. A depth of about
0.125 inch has been found to be satisfactory. At reference numeral 78, a
sheet formed from a material such as titanium (for example about 0.125
inch thick) or carbon steel (about 0.0625 inch thick) is placed above the
pyrite layer. The process is then reversed, and at reference numeral 80,
a layer of iron pyrite is placed over the sheet. A depth of about 0.125
inch has been found to be satisfactory. At reference numeral 82, a layer
of glass-filled nylon polymer washed using the wash liquid is placed over
the layer of iron pyrite. A depth of about 0.125 inch has been found to
be satisfactory. At reference numeral 84, a layer of brass granules
(about 35 mesh or finer) is placed over the layer of glass-filled nylon
polymer. A depth of about 0.0625 inch has been found to be satisfactory.

[0033]At reference numeral 86, a cover is placed on the mold and the mold
is placed in an oven at a temperature of, for example, 800° F. for
an interval of about 15 minutes, or until the glass-filled nylon polymer
begins to melt. At reference numeral 88, the mold is then removed from
the oven and immediately placed in a press rated about 50-100 tons where
the mold cover is uniformly pressed into the mold until the material
cools to a temperature of about 140° F. At reference numeral 90,
the finished placed is then released from the mold.

[0034]While embodiments and applications of this invention have been shown
and described, it would be apparent to those skilled in the art that many
more modifications than mentioned above are possible without departing
from the inventive concepts herein. The invention, therefore, is not to
be restricted except in the spirit of the appended claims.